Wire shaving apparatus



March 8, 1955 Filed June 22, 1951 A. H. BROQKES ETAL WIRE SHAVING APPARATUS 3 Shee'ts- Sheet 1 INVENTORS Albert H. Brooke: Leonard J. Rioqcr HEIR ATTORNEY March 1955 A. H. BROOKES ETAL WIRE SHAVING APPARATUS Filed Jim 22, 1951 3 Sheets-Sheet 2 INVENTORS Albert H. Brooke:

Leonard J. Ringer Leroy/.. Martin THEIR ATTORNEY March 8, 1955 Filed June 22, 1951 A. H. BROOKES ETAL WIRE SHAVING APPARATUS 3 Sheets-Sheet 3 l N VENTORS Albert H. Brookes Leonard J. Riogei roy Martin Y Ct dJ THEIR ATTORNEY United States Patent WIRE SHAVING APPARATUS i Albert H. Brookes, Golden, Colo., and Leonard J. Rieger and Leroy L. Martin, Baltimore, Md., assignors to Armco Steel Corporation, a corporation of Ohio Application June 22, 1951, Serial No. 232,964

Claims. (CI. 90-24 Our invention relates in general to the finishing of metal stock. More particularly it concerns imparting an adequate finish to wire stock, rods, bars and the like formed of stainless steel and other metals of substantial hardness, and especially of polyegonal section.

An object of our inventionfth refore, 18 to provide a method of nicely finishing metal bar, rod and wire stock, and this substantially without regard to cross-section and particularly suited for hexagonal stock, which method requires but few procedural and manipulative steps, each simple and rapid, and demanding only conventional and readily available equipment, and which s characterized by a basic simplicity, low costof production and rapidity of operation.

Another object is to provide apparatus for finish ng hard metal stock of small cross-sectional dimensions, 1mparting high finish detail with close adherence to small permissible tolerances, and while effectivelyand rap dly finishing stock of intricate cross-section, is simple 111 design and ready and economic of production, wh ch apparatus displays long useful life in the substantial absence of constant supervision and attendance, and whlch, while in use, is characterized by absence of moving arts. p A further object is to provide apparatus for achieving all the foregoing wherein the resulting product displays excellent finish detail, with no chatter marks, galling or weld marks, scarring, gouging, tearing or the like, and wherein shock, wear, clogging and the like of the apparatus are effectively minimized.

All these, as well as the many other highly practical objects and advantages which attend upon the practice of our invention will in part be obvious and in part pointed out during the course of the following description.

Accordingly, our invention resides in the combinations of elements, features of construction and arrangement of,

parts; and in the several procedural and manipulative steps, and cooperation of each of the same with one or more of the others, the scope of the application of all of which is more fully set forth in the claims at the end of this specification.

Inthe several views of the accompanying drawing, which disclose that embodiment of our invention which we presently prefer, and wherein like reference characters denote like constructional parts:

.Fig. 1 is a schematic showing of wire finishing apparatus in accordance with our invention;

Fig. 2 is an elevation of the wire-shaving apparatus of Fig. 1, partially in section;

Fig. 3 is an elevation, on enlarged scale, with parts shown in section, of one of a series of tool holders employed in our new wire-shaving head;

Fig. 4 is a perspective of the apparatus of Fig. 2; and

Fig. 5 is a perspective view, somewhat skeletonized,

disclosing the cooling and lubricating system for the cutting tools of our apparatus.

It will be helpful to a full understanding of our invention to point out at this point that difliculty has'confronted the industry in achieving superior finish for elongated metal stock of small cross-sectional dimensions such as bars, rods and wire, and displaying a high degree of hardness. Particularly is this true where in section, the metal periphery is polygonal, illustratively hexagonal. Moreoven'especial difiiculty is encountered in the rocessiilig .of bar, rod or wire stock formed of stainless stee 2,703,512 Patented Mar. 8, 1955 Because of the important use of stainless steels in the fabrication of articles in which surface perfection is mandatory, heavy emphasis is placed upon the initial production of wire stock free from known and not unusual defects, illustratively seams, minute slivers, imbedded scale, pits, laps and the like. And this, without concession whatsoever to which hexagonal configuration is illustrative. The distressmg frequency of occurrence of these defects has long been recognized, and they have been the subject of wide spread and intensive studies by those skilled in the art. This is particularly so where the nature of the section will not permit the removal of surface defects by conventional grinding equipment.

Despite the processing heretofore resorted to, the sought-after highly polished, lustrous and pleasing appearance has proved elusive; and the actual product has displayed itself as streaked, frosty and dull. At most, costly after-treatment, such as grinding, polishing or bufling, where it is possible, has had to be resorted to. While frequently where intricate shapes are required, the impracticabilityof after-treatment has made impossible the achievement of the desired excellent appearance of the fabricated metal stock.

Much study has been given to properly processing stainless steel and generally similar hard-metal wire stock, rods and bars, premised in part on prior work with softer metals such as copper. None of the many proposals suggested, however, has proved entirely adequate.

An important object of our invention, therefore, is to provide a method and apparatus for mechanically shaving stainless steel bar, rod, wire, and the like, particularly those of non-circular section and especially hexagonal stock, so as to eliminate substantially all surface defects, and this without necessity of preliminarily straightening the wire, wherein close tolerances are achieved, with smooth bright metallic finish; in which method and apparatus a hexagonal or other non-circular sectional is achieved true throughout its extent and provided with sharp edges or corners and this with required high accuracy of dimension and in the substantial absence of slivers or tears; and in which method and apparatus comparatively high operational speeds can be resorted to with required good results, such wear as does occur being directed, largely towards readily replaceable parts.

In the practice of our invention we find that for effective and rapid processing, and this with economy and through the use of simple and standardized equipment, it is required that simple, standardized cutting tools be employed having regular unbroken cutting edges. And

this is required nomatter how complicated be the configuration in section of the wire, rod or other stock undergoing finishing.

Accordingly, we provide a separate, bladed cutting tool for each face of the wire, rod, or other metal stock undergoing processing. And we back up the stock at a point opposite the cutting tool. We operably pair these tools in so far as is possible, in opposed relationship to minimize and even balance out the resultant effective stresses. We apply the cutting tools simultaneously against the metal stock throughout the shaving process. This is expedient both for proper and effective distribution of stress and for maintaining cutting speeds at highest practical limits. Moreover, it makes possible reduction of the wire stock through shaving operation and under cold-drawing conditions, down to required pleasing surface appearances and required finish dimensions. In this manner we can successfully ple and unrelieved configuration.

Effective means are provided for preventing the burning of the metal stock as a result of friction loading; the cutter blades are relieved against biting into the metal stock, and thus retain their sharpness. Welding of the freshly cut metal to the cutting tool is suppressed. Undethe intricacy of section, of

employ cutting tools of simit is apparent at once, however, that we are not restricted to scraping action alone, and a true cutting stroke is within the contemplation of our invention; Accordingly, we use the term "cutting" to indicate either a cutting or a scraping action.

With the foregoing in mind, reference will now be made to the specific embodiment of our invention shown in the several views of drawings. While this embodiment, with slight modifications, can be adapted to shaving stainless steel or other refractory metal stock of varied cross-sectional configuration, it has particular utility in shaving wire stock of hexagonal section. Moreover, while readily adaptable to the treatment of wire stock which in section, possesses an odd number of faces, say three, five, seven or the like, it has particular utility in working wire possessing an even number of faces, with opposed faces paired with each other, illustratively four, six, eight faces and the like, this, for the reason that the substantial stresses which can be applied from opposite sides against the paired faces tend to balance out each other.

The shaving head, indicated generally at in Figs. 1 and 2 is mounted to a standard wire-drawing bench, indicated generally at 11. Since the particular bench employed does not in itself, form part of our invention, no detail description of it is made in the drawings, this for simplicity and clarity. Bench posts 12 and 13 are employed on which to carry shaving head 10. Both posts are formed of heavy metal to suppress play, with possibility of resultant chatter.

Post 12, provided at the left end of the shaving head, Fig. 2 pivotally carries that end of the shaving lread and attaches to the floor mount 12a. The post 13 near the right end of the shaving head in Fig. 2, and disposed perpendicularly to bench 11 carries the shaving head 10 near the tail or exit end thereof.

We provide a guide block 14 of wood, having a central opening 14a through which the wire passes. Thence the wire is lead across chamber 15, containing soap or generally similar solid lubricant. As a final preliminary, the wire is drawn through a hexagonal cold-drawing die indicated generally at 16 and disclosed in Figs. 2 and 4 as provided with a water-cooling system 16a. Here the final cold reduction of the metal stock to calibrated oversize is achieved.

Conveniently wooden block 14, soapchamber 15 and die 16 are contained in metal holder 17, which is sufficiently massive to suppress all tendency toward vibration or other undesired bodily movement of either the wire stock or the shaving head. Entrance and exit through holder 17 respectively are had through plates 18 and 19, each with a corresponding central orifice 18a and 19a.

When shaving stock of hexagonal section, six tool holders are employed, one for each face of the metal stock. The assembly of six tool holders is best shown at the right in Fig. 1. Six rods 21, 22, 23, 24. and 26 are carried between corresponding headers 27 and 28, these headers in turn, being carried from the posts 12 and 13. These rods are made of heavy metal stock to suppress vibration and chattering, and extend through the headers 27 and 28 and are made fast thereon by suitable conventional lockdown means such as lock nuts 29.

The tool holders. six in number. are indicated generally at 31, 32, 33, 34, and 36 in Fig. 2. Eachtool holder is carried on a corresponding four of the horizontally extending rods and separated from the other by cylindrical sleeve spacers. Each tool holder is substantially like the the body portion 31a, and in the embodiment undergoing description and disclosing tool holder 31, the body portion 31a is wider at extremities 31b and 310, to provide enlarged bosses 31b and 31b" for the one end and 31c and 31c" for the other whereby the holder may be received on the appropriate rods. Illustratively, holder 31 is mounted on rods 22, 23 and 25, 26. Body portion 31a is machined as at 311 to provide containing surfaces throughout most of its longitudinal extent. We provide a tool post holder 31g in the upper part of slot 31f. Through this tool post holder and extending longitudinally of the body portion 31a passes a tool post 311:. We mount a shaving tool 311' bodily on the post 31h and this post is adjustable longitudinally through tool 0st holder 31g relative to the wire stock indicated genera 1y at 20, Fig. 3. While any suitable adjustment can be provided, in the preferred embodiment we provide threads on post 31h so that it may be threaded lengthwise along and relative to an adjusting nut 31 which in turn is threaded into tool post holder 31g. Hence by turning nut 31j relative to holder 31g, the shaving tool 31i can be adjusted with the utmost nicety relative to the metal stock 20. Once ad justed to its proper position, the cutter tool 311' may be locked in such position by suitable means, here shown as lock-down set screws 31k threaded laterally through the holder 31g and seating against the tool post 3111.

Also carried within slot 311, we provide a roll yoke 31m fitting snugly within the bottom thereof, this being U-shaped as illustrated in Fig. 3. A shaft 31;: is mounted laterally within the roll yoke 31m and carries suitable antifriction bearings, one being shown as roller bearing 310, which extends well into the slot 31f. Finally, a backup roll 31;; is carried on roller bearings 310. This backother tool holder, the object being to present the cutter blade of a particular tool holder against that face of the wire stock which is to be shaved by that cutter. Thus, any particular tool holder is carried by that four of the six rods which, when the tool holder is properly positioned thereon, will result in its shaving blade being automatically brought against the proper and intended face of the metal stock. Thus. with the hexagonal stock being fed longitudinally through the shaving head in Fig. 2, and with one hexagonal face thereof disposed topmost and horizontally. tool holder 31 will be so disposed that the shaving blade thereof will be brought into contact with the upper and horizontal face of the metal stock.

A typical tool holder 31 is disclosed in Fig. 3. It is evident therefrom that each such tool holder comprises a body portion 310. This body portion, elongated and massive, extends between particular rods ofthe rod system 21 through 26 which supports this particular tool holder. As shown in Fig. 3, these rods are paired at each end of up roll is made of hard bronze.

Roll yoke 31m is made bodily movable within the bore 31 so that the back-up roll 31p may be made adjustable relative to the metal stock 20. Such adjustment is accomplished by means of a set screw 3Iq which extends through the bottom web 31b of the body portion of the tool holder and is threaded into yoke 31m. Upon rotation of set screw 31: this roll yoke is carried bodily along the slot 31 relative to the metal stock 20.

While of course cutter 31i may be formed of any suit able cutting steel or other material displaying required physical properties, in the preferred embodiment here disclosed we employ a cutter form of Tantung G alloy. The cutters are about three-quarters of an inch in width and about one-eighth of an inch thick. They are screwed to the tool post, shown as screw 311' for cutter 311' on post 31h. It will be seen therefore that the cutters easily may be removed for sharpening and replacement.

Other advantages of our invention, as have already been referred to, reside in the fact that the construction is such that-the cutting edge of the tool is regular, unbroken and linear across its face, requiring no contouring to the cross-sectional shape of the metal stock 20. Thus, the cutting tool can be readily produced from available cutting tool stock with rapidity and at a minimum of operating steps, and when required, can be re-edged with minimum shut-down. In order to provide the scraping action which we find most advantageous we impart a 5 negative rake to the cutting tool. This provides an 85' angle between the cutter tool 311' and the particular surface of the metal stock 20 which is being shaved.

Back-up roll 31p applies, the metal stock 20 under requisite loading against the cutter tool 31f. For reasons pointed out later in this disclosure, these back-up rolls are formed of hard metal stock, illustratively hard Ampco bronze, or some other metal displaying a hardness of, at least Rockwell B 80-90.

During the cutting action we apply a suitable lubricant against the cutting edge of the various cutters and metal stock 20, supplying the same through main supply pipe 37, Fig. 5, into header 38 with control valves 39. Thence the lubricant is led to the separate tool holders 31 through 36, through lateral supply ducts feeding conduits 41 through 46. Each conduit in turn leads to region of contact between the particular cutting tools and the work 20, and supplies a cutting lubricant to the work. This lubricant is employed to cool and lubricate the corresponding cutting tool. Preferably we employ that typical cutting lubricant known as Lusol, diluting this with 20 parts of water. This coolant is projected directly and at some pressure, against the cutting tool and work stock, electively preventing undue heating and carrying away the metal chips from the region of cutting.

Following discharge onto the cutting tool and work,-

the cooling li uid flows into the overflow pan 47 carried by the draw bench and displayed beneath the shaving head 10, and drains off through overflow pfifpe 48 to collecting reservoir 49. Thence it is drawn through the valved discharge outlet 50. The used lubricant is screened and recirculated for further use. By proper control of the quantity and temperature of the coolant, both the cutting tool and metal stock may be maintained at safe permissible temperatures throughout the shaving operation.

The tool holder 31 is shown inFig. 3 as being applied to the topmost face-of themetal stock 20. As shown in Fig. 2, the tool holder 32 is applied to the top left face 0.386" hexagonal col of hexagon as shown in Fig. Band to this end, body portion 320 of holder 32 is mounted on rods23, 24 and 26, 21. Similarly tool holder 33 is applied to the bottom left face of the work stock 20, and to this end, the body portion thereof is mounted on 24, and 21, 22. Likewise tool holder- 34 is applied against the bottom hexagonal face of the work and to this end, the body portion thereof,'is mounted on rods 25, 26 and 22, 23. And it being desired to apply the cutter of tool holder 35' against the bottom right face of work stock 20, the body portion of this holder is mounted on rods 26, 21 and 23, 24. Finally, it being desired tomount the tool holder 36 so that its shaving blade is applied to the upper right face of the metal stock, this tool holder is mounted on rods 21,

22 and 24, 25. v

It is to be noted that in the disposition of the rods and tool holders the following pattern has been adopted; the rods 21 through 26 are disposed symmetrically with respect'to the longitudinal axis of the shaving head and are arranged at the apices of asymmetrical and equi-angle hexagon; that is in section the rods are 60 apart from each other. The rods are spread at such distance apart from each otherand are formed of metal of such gauge as to impart substantial rigidity to the structure without adding to the initial cost thereof. To the same end of achieving substantial rigidity, we make the rods of sufiicient length and space the tool holders at equal distances therealong and with such distances between adjacent tool holders as is best calculated to eliminate undue torsional stresses resultingin play, whip and the like. As a final therefore, the die 16 conveniently takes the form of an -drawing roughing die.

To achieve best results with our apparatus the exercise of certain precautions is necessary. Thus, it is particularly important that the faces of the wire to be shaved are prepared so as to lie exactly parallel to the cutting edges of the cutter blade. To this end, we find it necessary to point the lead end of each coil providing thereon a long tapered point, round in section, and approximately six feet in length. This lead point is prepared with great care, following which the coils of wire are pickled and limecoated. In preparing the six feet long .lead spike. care must also be taken to prevent twisting the wire. We

found the use of the roll straightener to be hel ful in this connection in that it not only removed the ks from the wire, but facilitated maintainin non-kinking by providing at least some degree of bac tension on the wire stock. Our experience has shown that the long lead \point should be as straight as possible and that in particular, no twist whatsoever can be tolerated where the rounded section of the point merges at its base into the hexagonal shape of the wire proper. We find that such a twist, will turn the wire in the die or under the cutter and will cause gouging of a corner of the wire.

With the foregoing precautions observed, we then back ofi all six cutters and rolls of the tool holders by letting off the set screws, respectively. Under these conditions we are enabled readily and easily to thread the elongated precaution we disposed the tool holders symmetrically,

both around and along the rods, so that with tool holder 31 applied against the upper face of work stock 20, the tool holder 34 will be the fourth removed along the length the rods and will be paired with tool holder 31, and is applied againstthe opposite or under-face of work stock 20 (Fig. 3). Similarly tool holders 32 and 35, four removed from each other along the length of rods, are paired and applied against the bottom right and upper left faces respectively, of the work. Finally, tool holders 33 and 36, likewise four removed from each other along the rods are paired and applied against the upper right and lower left faces, respectively, of stock 20. In this manner stresses, both torsional and longitudinal, are minimized and neutralized in so far as possible, by balancing out.

In operation, the wire stock, carried on an appropriate reel 51 at the head end of the bench, is led through a straightener 52 having a plurality of horizontal rolls 52a and a plurality of vertical rolls 52b, through guide plate 18, through orifice 14a of wood block 14, through soap chamber 15 and through hexagonal cold-drawing die 16. And from die 16 the metal rod 20 is led through the set of tool holders 31 through 36 of the shaving head, and is thence carried by horizontal rolls guides 53 to the power drum 54 of the drawing bench. We find it to be highly advantageous to employ a series of vertical rolls as a guide between the shaving head and the power block in order that the wire at all times may be centered as it leaves the shaving head. The power block also serves to coil the finished wire.

While our invention has particular application to finishing hexagonal stock sizing between inch and /2 inch,

across fiats, it is ,also applicable to various other sizes of stock. In a typical employment we treat a coil of wire 310 pounds in weight, and which has been brought through cold-drawing technique to 0.406 hexagonal size. The wire displays minor surface imperfections as it passes to our new shaving head. In'the present embodiment,

lead point of the wire stock through the shaving head 10. Several wraps of wire are firstdrawn from the take-off reel 51 (see Fig. 1) onto the drawing bench 54 with only the drawing die 16 in contact with the wire. With the wire maintained under tension and under steady flow conditions of the wire stretched across the shaving head, the first cutter of the series, that of shaving tool 31 (see Fig. 2), isadjusted against the metal stock 20 so as to make a light out on the corresponding or top face of the metal. The set screws of cutter 31 are then locked down for proper operation. Next, the back-up roll of the tool holders is moved in to bear against the opposite surface of wire 20, for light contact thereagainst. Thereupon, tool holder 34, paired with holder 31, the bottom face-of the metal stock and applied against the top surface. achieved. Cutting tools of tool holders 32 and 35 and their respective back-up rolls are then applied with equal tension against the corresponding faces of the metal stock. Following this, cutting tools of tool holders 33 and 36 and their back-up rolls are applied so as to make a cut. We prefer to make all cutting adjustments while the wire is in motion to achieve dynamic balance.

When so operated we find that, for the typical embodiment noted above, the shaved wire finished to a hexagon of 0.3819-0382" across flats. A smooth clean metallic finish was observed. The cutting operation imparted sharp corners to the hexagon and this with no tear. The section of the wire was nicely controlled from the dimensional standpoint. All adjustments to both the tool and the back-up roll were easily made, and this during operation. By merely guiding the chips away from the region of cutting and from contact with the back-up rolls all tendency to ward gouging was eifectively avoided.

Our-observations disclose that a wide range of speeds is available within which desired good results can be achieved. The best operating speeds for the example noted range from about 70 to feet per minute. We observed that when the shaving speeds were too low a ragged and torn edge was produced. Where the speed was too great, chatter marks on the wire were observed, along with tendency toward vibration. By proper choice of metal of the cutting tool and of the back-up roll and by proper choice of composition, temperature, qualilty and rate of flow of the combined lubricant-coolant, a rather wide variation in the permissible rate of speed can be achieved.

Through the practice of our method, particularly with reference to our new shavi g assembly, the rapid production of shaved wire of non-circular section is rendered expedient. Such wire displays a highly desirable finish details satisfying the most exacting requirements. Moreover, care has been exercised in eliminating and avoiding the necessity of highly specialized equipment. As a result, investment in plant its back-up roll is is applied against Static balance is thus I large output of each work station in the plant. Labor requirements are appreciably reduced, and this from both quantitative and qualitative standpoint. Shutdown due to replacement and repair is brought to a minimum.

While the invention has particular application to wire formed of stainless steel, it is also applicable to stainless steel straight-length bar and rod stock of sub stantially larger diameter, resulting in superior finlsh thereof.

With the foregoing in mind, it will be readily appreciated that many modifications of our invention W11]. suggest themselves to those skilled in the art, accordingly, therefore, we intend the foregoing description to be considered as illustrative, and not by way of lun- We claim:

1. Apparatus for mechanically finishing wire stock of refractory metal comprising in combination, a multiplicity of cutting elements, each of regular, unbroken edge, spaced from each other and supported about the stock; roller means backing up the stock opposite each of said cutting elements; and means for drawmgthe stock in one pass through a shaving zone, across all said cutting elements.

2. Apparatusfor mechanically finishing metal stock of polygonal sections, comprising in combination, means for drawing the metal stock, under tension, and in once-through pass, through a shaving region; a shaving head disposed in said shaving region an through which the said metal stock passes; and a series of cutter tools provided on said shaving head in spaced relation to each other, both longitudinally and angularly, about said stock in said shaving zone, one for each face of stock, and each cutting tool carrying thereon and as part thereof a cutter blade having a regular cutting edge of unbroken surface, and possessing negative rake.

3. Apparatus for mechanically finishing multi-faced metal stock comprising, in combination, a die; means for drawing the metal stock through said die and under tension in once-through pass through a shaving region; a shaving head disposed in said shaving region and through which the said metal stock passes; a series of cutter tools provided on said sha head in spaced relation to each other, both longitudinally and angularly, about said stock in said shaving zone, one for each face of the stock, each cutting tool thereon and as part thereof a cutter blade having a regular cutting edge of unbroken surface; and means for playing a coolant and lubricant on both the cutting' blades and the metal stock in the region of shaving.

4. A shaving head for simultaneously and m anically finishing, in a once-through pass, all faces of metal stock of multi-faced section, comprising a corresponding multiplicity of rods extending longitudinally of said shaving head and disposed in regular polygonal pattern when viewed in section; and a like number of like cutter tools carried along the length of said rods and each carrying a cutter blade of smooth, unbroken and continuous cutting edge, there being one such cutting tool for each face of the metal stock.

5. A shaving head for simultaneously and mechanically finishing, in a once-through pass, faces of metal stock of hexagonal section, comprising six support rods extending longitudinally of said shaving head and disposed in regular hexagonal pattern when viewed in section; and a like number of like cutter tools carried along the length of said rods and each carrying a cutter blade of smooth, unbroken and continuous cutting edge, there being one such cutting tool for face of the metal stock, the cutter tools being paired, so that those tools which are three removed from each other along the rails are applied against opposite faces of the metal stock.

References Cited in the tile of this patent UNITED STATES PATENTS 218,249 Fields Aug. 5, 1879 1,317,049 Smith Sept. 23. 1919 1,439,370 Lambert Dec. 19, 1922 1,706,393 Fay Mar. 26, 1929 1,832,719 M'cBerty Nov. 17, 1931 2,120,316 Stone June 14, 1938 2,153,431 Osberg Apr. 4, 1939 2,233,928 Weaver Mar. 4, 1941 2,638,818 Stevens May 19, 1953 

